This application claims benefit of U.S. Provisional Application Serial No. 63,122,565, entitled, “Plug and Play Digital Panel Meters Replaces 100% Form, Fit, & Function Analog Meters” filed Jun. 4, 2021, the entire disclosure of which is incorporated herein by reference.
The present disclosure is generally related to meters and more particularly is related to meter replacement systems.
Many industrial, commercial, and military facilities use numerous meters, gauges, and other reading devices to measure or determine various properties of the facility's operation. For instance, a nuclear power plant with one reactor may typically use between 300-800 meters to allow workers to read various properties of nuclear power generation, such as temperature, pressure, flow rate, electrical output, or many other properties of the facility's operation. However, in many of these facilities, the meters were first installed when the facility was originally built, and as such, the meters are outdated or obsolete analog meters. In nuclear power plants, for instance, the meters in the control rooms are usually between 30-50 years old. Because these meters are so outdated, there are very few, if any, manufacturers or suppliers who can replace or repair them when needed. When one of these meters falls into disrepair, it is very difficult to repair it to a working state again. As such, there exists a continually growing problem with the obsolescence of the instrumentation in the control room of an industrial facility.
To overcome these problems, some industrial, commercial, or military facilities may be required to fully renovate their control rooms to remove the existing outdated analog meters and replace them fully with new, computer-controlled sensors and meters. However, for many facilities, such as nuclear power plants, they are too old and have too short of a life expectancy to justify fully overhauling their control rooms, nor do they have the money to invest in the facility. Instead, they must rely on fixing and replacing individual meters when they stop functioning as needed. This problem is often present in nuclear power plants, in water treatment plants, military installations, and ocean vessels.
However, a typical facility which uses these meters may have upwards of 500 meters, and of those meters, there may be 5-10 different sizes and shapes for the meters. As such, within the conventional art, there is not one single meter design which can function for the varying sizes and shapes of the meters. Additionally, there are usually 30-40 different input signals received by the meters, including, for example, temperature, pressure, humidity, volts, amps, frequency, and others. While some facilities have spare meters in storage to use for replacing malfunctioning meters, the scale visible on the meter's faceplate (on its visible front side) also needs to match the property of which the meter is measuring. For instance, a voltage meter having a voltage scale would need to be replaced with another voltage meter having the same voltage scale, and not a meter having a scale with percentage, or a different minimum/maximum, or a pressure range. Thus, despite that fact that the meters in these facilities may be similar in original design, these other factors often prevent convenient and affordable replacement of a meter.
In one aspect of the invention, a replacement meter system is provided having a meter housing and mounting assembly adaptable for retrofit within any instrument panel. The retrofit can be accomplished without any modifications to the instrument panel, wiring, or display, and can be installed by personnel without special training.
In another aspect of the invention, a replacement meter system is provided having a universal signal conditioning module insertable within the housing and mounting assembly and having “plug in” signal conditioners capable of receiving a wide range of input signals. The module allows for the automatic determination of wether the meter is “loop powered” or externally powered, and allows for a plug in power module for meters requiring external power.
In another aspect of the invention, a method of replacing one or more meters in an instrument panel is provided. The method involves the steps of selecting a meter housing and mounting assembly that fits the space in the instrument panel; selecting the grade (nuclear, military, or industrial) of the meter; selecting an appropriate sized and configured adapter plate if the selected meter housing is different than the old meter housing, the adapter plate part of the mounting assembly; selecting a plug in signal conditioning module based on the input signal; selecting a plug in power module if the meter requires external power; and selecting a scale plate or display filter to be affixed to the front face of the meter housing, the display filter corresponding to the parameter to be measured by the meter. Additional steps may be taken to further customize the replacement meter. The method, using the adapter plate, plug in signal and power modules, and display filter, allows for replacing meters of virtually any size or shape in an instrument panel without the need for soldering or rewiring thereby greatly saving installation time and effort. Also, once the appropriate adapter plate is determined, the installer only need know the input signal and power requirements, and the parameter to be measured so that the installer needs no special training.
In another aspect of the invention, the front surface of the meter housing is a neutral white color to allow for the visualization of the indicia and coloring of a display filter. The translucent display filter is affixed to the front surface of the meter either by adhesive or mechanical means and is used to the indicate the parameter being measured, e.g., volts, the neutral white color of the front surface of the meter housing allowing the relatively dark indicia on the display filter to be viewable.
In another aspect of the invention, the replacement meter system that avoids the use of devices/components that require firmware or software subject to criminal breach. The hardware only design of the present invention meets strict requirements of the industry to reliably and accurately operate within the present limited power available to analog meters technology such as 1-5 and mainly 4-20 mA current loops as well as alternating current known as household power and direct current used in industrial applications, just like present analog meters do and also externally powered meters used for sub-microwatt applications.
Embodiments of the present disclosure provide a system and method for providing a single movement display meter. Briefly described, in architecture, one embodiment of the system, among others, can be implemented as follows. A single movement display meter includes a display input wherein the display input receives and transmits a display input signal containing information relative to only one property. A digital display is positioned to receive the display input signal and represent the digital input signal within a display, wherein the digital display has a front surface. A display filter mounts on the front surface of the digital display. A hub includes an input connector connectable to one or more wires to receive a hub input signal. A signal modification module connected to the input connector is capable of modifying the hub input signal to output the display input signal. A hub output communicates with the display input to transmit the display input signal.
The present disclosure can also be viewed as providing methods of providing a single movement display meter. In this regard, one embodiment of such a method, among others, can be broadly summarized by the following steps: receiving a display input signal with a display input, wherein the display input signal contains information relative to only one property; receiving the digital input signal from the display input with the digital display, wherein the digital display has a front surface; and mounting a display filter to the front surface of the digital display.
The present disclosure can also be viewed as providing methods of systematically replacing one or several meters in an instrument panel. The method, in one embodiment, allows for the efficient and relatively inexpensive replacement of multiple meters in a facility by providing a highly adaptable and configurable meter system having interchangeable components. The appropriate interchangeable components are easily determined by the installer, and the installation can be accomplished without specialized training or detailed installation instructions. Once the physical mounting requirements are known, the method provides for “plug and play” installation with plug in modules providing signal conditioning and power. In other embodiments of the method, additional steps are taken to further customize the replacement meter.
Other systems, methods, features, and advantages of the present disclosure will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the present disclosure, and be protected by the accompanying claims.
Many aspects of the disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
To overcome the aforementioned problems in the conventional art, the subject disclosure is directed to improvements for meters, including mechanical and electrical components for the repair and replacement of meters. In particular, the subject disclosure is directed, in part, to a retrofittable meter replacement system which allows for convenient and efficient replacement of a conventional meter which has malfunctioned or otherwise needs replacement.
For the single movement meter 10, the movement displayed on the single movement display meter 10 may be an illuminated display bar 14, as shown in
To use the single movement display meter 10 with a specific parameter, such as to display an electrical measurement, a pressure measurement, or a similar parameter, a display filter 20 is attachable to the front surface 12 of the single movement display meter 10. Various display filters 20 are illustrated in
The use of the display filter 20 may provide significant benefits in the industries where meters require replacement. When desired, a user can replace a malfunctioning meter with a single movement display meter 10, and then select the appropriate display filter 20 for the parameter that the single movement display meter 10 measures. Accordingly, a user who requires a pressure meter would put a pressure display filter 20 over the single movement display meter 10, such that when the display bar 14 is illuminated, a user could identify the pressure on the single movement display meter 10. With this single movement display meter 10 and the variety of display filters 20, any identical size and shape of the meters 10 can be used with any property detection or measurement. Additionally, because the display filter 20 is placed on the outside of the front surface 12 of the single movement display meter 10, versus conventional meters where the display is factory sealed within the housing of the meter, it is easy to change the display filter 20 when re-purposing the single movement display meter 10.
In order to utilize the single movement display meter 10 in the desired physical setting, the meter replacement system may include the use of a hub 30 and an adapter plate 40 which provide the electrical and mechanical connections between the single movement display meter and electrical and mechanical infrastructure of the facility, respectively.
The hub 30 may have various shapes, but in one example, the hub 30 is substantially cylindrical such that it can fit through one or more adapter plates 40 which aids in mounting the hub 30 to the single movement display meter 10. In particular, the body of the hub 30 may be positioned through a central aperture 42 of the adapter plate 40 such that the output port 36 of the hub 30 can engage with a display input located on a rear side 13 of the single movement display meter 10. The electrical connection between the hub output port 36 and the display input may be achieved by any known electro-mechanical connections, such as by threading a holding nut 38 or collar of the hub 30 on to a threaded receiver 11 on the single movement display meter 10, whereby the mechanical connection (threaded, friction-fit, biased, or otherwise) ensures an electrical connection between the hup output port 36 and the display input. In this position, the hub 30 is also positioned through an aperture 6 of an existing panel 4 within the facility, thereby allowing the single movement display meter 10 and hub 30 to be mechanically retained in the desired location for display to a user. For example, the existing panel 4 may be located within the control room of the facility, such that the meter replacement system 100 can be used to provide a new, working meter in the same panel 4 as the meter that required replacement. Optionally, one or more gaskets or O-rings 44 may be used to ensure a tight mechanical connection and prevent the intrusion of foreign contaminants, e.g., moisture, dust, etc. into any of the electrical connections.
More specifically, the adapter plates 40, as shown in
The displays (digits or bar) automatically detect whether the display input signal from the hub output port 36 is “single ended” (the negative input is grounded) or differential (both positive and negative inputs are floating) or the display input signal is negative as supplied by the hub output port 36 or input/output (I/O) module (
Since on 91-PNP78-00 “DL” is installed as well as RL1 and RL2, DL (reference) clamps the loop voltage to −4V a J11-4 and J11-1 (through RL2) and J12-1 to power the display through J1-1 (on 91-PNP-F-1 on −N-1) and return the current to switch 1 pin 7 to “SLIME” it after it has returned from the display (and other loads within the HUB) to −loop if and only if resistor RSE is absent, in other words: all loop current must flow through the entire circuit (display and signal conditioners plugged) to J11-3 and ST1-5 (−loop input) for accurate measurement and power of the display. The above is identical for either 4-20 or 10-50 mA current loops except for the value of R2 (10 Ohms) vs R7 (24.9 Ohms) to develop the full-scale signal of 0.5 Vdc (at 20 or 50 mA input) to be displayed. No other components are required for the “loop powered” mode.
Disclosures in co-owned prior patents are expanded here by including a field selectable signal conditioner for either current loop or externally power functionality of the display in the field (user) selectable function or input signal range as well as the compliance of configuring the signal for automatic differential or single ended requirement of the digital display 16.
The opto isolated open collector transistor (U2) can be used as a stand-alone for light loads under 50 mA and under 30 VDC, or to drive the power relay (K1) for heavy loads. The comparator (U1) can drive H.V. MOSFETS (SSR) and reed relays while loop powered. The unique automatic detection of either single ended or differential status of the input signal allows the hub 30 to be able to drive loads even when powered by the hub input signal it measures.
As illustrated in
The super capacitor C1 along with the selected series resistor (R1-R5) determines the “time constant” of the “forced” delay on the output current loop at ST1-8 (+loop out) and ST1-6 (+loop in of the KISPID and display via J12-4) and its output at ST1-5 (J12-3) that becomes the user's+loop in to control its process. In other words, this PID is a user's selectable “time delay” to prevent an over or under shoot to allow the driven process to “react” to the hub input signal, eliminating this over or under “shoot.” It should be noted that this PID module is developed without any software. As a hardware-only system, it does not rely on memory devices or require software upgrades.
For experimental purposes (learning how the specific user's process reacts to the optimum time delay [by C1 and R1-R5], SW1-7 is used to force C1 [0.1 FARAD] to discharge instantaneously).
The limit adjust of U1 via P1 is typically set at −90-95% of full scale to enable C1 to charge through SW1-1 through -5 for desired time constant of 10-100 seconds with any other ranges selected by changing the values of R1-R5.
As is shown by block 502, the process begins by receiving a hub input signal with an input connector of a hub. A signal modification module modifies the hub input signal module to output the display input signal (block 504). The hub output transmits the digital input signal to the display input (block 506). A display input receives the display input signal, wherein the display input signal contains information relative to only one property (block 508). The digital display receives the digital input signal from the display input, wherein the digital display has a front surface (block 510). A display filter is mounted to the front surface of the digital display (block 512).
Any number of additional steps, functions, processes, or variants thereof may be included in the method, including any disclosed relative to any other figure of this disclosure.
It should be emphasized that the above-described embodiments of the present disclosure, particularly, any “preferred” embodiments, are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the disclosure. Many variations and modifications may be made to the above-described embodiment(s) of the disclosure without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and the present disclosure and protected by the following claims.
This invention was made with United States government support under contract number ______ awarded by the ______. The United States government has certain rights in this invention.
Number | Date | Country | |
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63122565 | Jun 2021 | US |